Professional Documents
Culture Documents
com
rcsaini.blogspot.com
Numerical Control
Numerical control is a method of automatically operating a manufacturing machine based on a code of letters, numbers, and special characters. The numerical data required to produce a part is provided to a machine in the form of a program, called part program or CNC program.
The program is translated into the appropriate electrical signals for input to motors that run the machine.
rcsaini.blogspot.com
rcsaini.blogspot.com
rcsaini.blogspot.com
rcsaini.blogspot.com
CNC Machines
Machining Centers, equipped with automatic tool changers, are capable of changing 90 or more tools. Can perform milling, drilling, tapping, boring on many faces.
rcsaini.blogspot.com
CNC Machines
Turning Centers are capable of executing many different types of lathe cutting operations simultaneously on a rotating part.
rcsaini.blogspot.com
CNC Controllers
The NC controller is the brain of the NC system, it controls all functions of the machine. Motion control deals with the tool position, orientation and speed.
Auxiliary control deals with spindle rpm, tool change, fixture clamping and coolant.
Many different types of controllers are available in the market (GE, Fanuc, Allen-Bradley, Okuma, Bendix, ). There are two basic types of control systems: point-to-point and continuous path.
rcsaini.blogspot.com
rcsaini.blogspot.com
10
rcsaini.blogspot.com
11
rcsaini.blogspot.com
12
rcsaini.blogspot.com
13
Decide which machining operations and cutter-path directions are required (computer assisted).
Choose the tooling required (computer assisted). Run CAM software to generate the CNC part program. Verify and edit program. Download the part program to the appropriate machine.
14
Block number
G06
G17 G20
G28
G33
16
Feed commands (F code) Used to specify the cutter feed rates in inch per minute. Speed commands (S code) Used to specify the spindle speed in rpm. Tool commands (T code) Specifies which tool to be used, machines with automatic tool changer.
rcsaini.blogspot.com
17
CNC machines milling machines can perform simultaneous linear motion along the three axis and are called three-axes machines.
rcsaini.blogspot.com
18
rcsaini.blogspot.com
20
rcsaini.blogspot.com
21
rcsaini.blogspot.com
22
Loading tool
Rapid motion
Tool change
rcsaini.blogspot.com
23
Tool dia.=10 mm
rcsaini.blogspot.com
24
14.14
25
Identify the part geometry, cutter motions, speeds, feeds, and cutter parameter.
Code the above information using ATP.
Compile to produce the list of cutter movements and machine control information (Cutter Location data file, CL).
Use post-processor to generate machine control data for a particular machine. This is the same as NC blocks.
rcsaini.blogspot.com
26
rcsaini.blogspot.com
27
28
CAD/CAM
CAD/CAM systems allow for rapid development and modifying of designs and documentation.
The 3D geometric model produced becomes a common element for engineering analysis (FEA), machining process planning (including CNC part programming, documentation (including engineering drawings), quality control, and so on.
The coupling of CAD and CAM considerably shortens the time needed to bring a new product to market.
29
Some available software; SDRCs Metaphase, Unigraphicss IMAN, Computer Visions Optegra.
(web-enabled software).
rcsaini.blogspot.com
30
rcsaini.blogspot.com
31
The electrode (plunger) can be a complex shape, and can be moved in X, Y, and Z axes, as well as rotated, enabling more complex shapes with accuracy better than one mil. The spark discharges are pulsed on and off at a high frequency cycle and can repeat 250,000 times per second. Each discharge melts or vaporizes a small area of the workpiece surface.
The amount of material removed from the workpiece with each pulse is directly proportional to the energy it contains. Plunge EDM is best used in tool and die manufacturing, or creating extremely accurate molds for injection-molding plastic parts.
rcsaini.blogspot.com
32
EDM
The dielectric fluid performs the following functions: It acts as an insulator until sufficiently high potential is reached . Acts as a coolant medium and reduces the extremely high temp. in the arc gap.
More importantly, the dielectric fluid is pumped through the arc gap to flush away the eroded particles between the workpiece and the electrode which is critical to high metal removal rates and good machining conditions. A relatively soft graphite or metallic electrode can easily machine hardened tool steels or tungsten carbide. One of the many attractive benefits of using the EDM process. 33
rcsaini.blogspot.com
EDM
The EDM process can be used on any material that is an electrical conductor The EDM process does not involve mechanical energy, therefore, materials with high hardness and strength can easily be machined. Applications include producing die cavity for large components, deep small holes, complicated internal cavities Dimensional accuracy of 0.0005 in is achievable. Minimum wall thickness: .01 inch, over 5 inch span
34
Wire EDM
Wire EDM machines utilize a very thin wire (.0008 to .012 in.) as an electrode. The wire is stretched between diamond guides and carbide that conduct current to the wire and cuts the part like a band saw. Material is removed by the erosion caused by a spark that moves horizontally with the wire.
rcsaini.blogspot.com
35
EDM Examples
Intricately detailed automobile part 7075-T6 aluminum back plate latch, EDM cost is less than half the milling cost. These simple, flat shapes, used in food processing, which usually would be stamped, were wire EDMed instead because they required a superior quality edge.
rcsaini.blogspot.com
36
EDM Examples
To manufacture titanium earring shapes wire EDM proved the most cost effective when compared to stamping and laser cutting.
Turbine blades
Small gear (with insect for scale) shows a capability of EDM micromachining.
37
CNC Machines
Laser Machining and Cutting
The machine utilizes an intense beam of focused laser light to cut the part. Material under the beam experiences a rapid rise in temp. and is vaporized. Laser cuts with a minimum of distortion, no mechanical cutting forces. .
Gas is blown into the cut to clear away molten metals, or other materials in the cutting zone. In some cases, the gas jet can be chosen to react chemically with the workpiece to produce heat and accelerate the cutting speed rcsaini.blogspot.com 38
39
rcsaini.blogspot.com
40
There is quicker turnaround for parts regardless of the complexity, because changes of the design of parts can be easily accommodated. Laser cutting also reduces wastage.
rcsaini.blogspot.com
41
42
43